Apparatus for forming thermoplastic laminates into major sections

ABSTRACT

Apparatus for bending flat thermoplastic laminates into structural shapes such as angles, channels, Z sections, J sections and I sections. In order to bend the laminate into the desired shape by appropriate tooling, heat is applied in a localized manner only to the area that is to be bent. The application of heat is sufficient to heat the laminate to its softening temperature in the bend area, and the plies of the laminate can thus slip in the bend area only as bending force is applied so that the bend can be made without the need to heat the entire laminate to the softening temperature.

This is a division of application Ser. No. 817,282, filed Jan. 9, 1986and now U.S. Pat. No. 4,759,815, issued July 26, 1988, which is adivision of application Ser. No. 665,551, filed Oct. 29, 1984, now U.S.Pat. No. 4,583,935, issued Apr. 22, 1986.

BACKGROUND OF THE INVENTION

This invention relates in general to the field of thermoplastics anddeals more particularly with the forming of thermoplastic laminates intovarious shapes.

Because thermoplastic laminates have many desirable qualities, they arewidely used in a variety of applications. However, a major drawbackassociated with thermoplastic laminates is the considerable difficultythat is encountered in forming the laminates into the shapes that arenecessary for them to function as major structural members. The mostdesirable laminates are obtained by consolidating multiple plies intoflat sheets which harden when cooled to room temperature from theelevated consolidation temperature. Subsequent curving or bending of thelaminate requires that the plies slip relative to one another, and thiscan be achieved only if the laminate is heated to the softeningtemperature at which ply slippage can occur.

In the past, techniques common in the metal bending technology have beenused with thermoplastic laminates, despite the recognized differences inthe properties of thermoplastic as compared to metal. For example, theentire laminate and sometimes the bending tool are heated to thesoftening temperature of the thermoplastic to allow ply slippageanywhere in the laminate at the same time. As can easily be appreciated,this technique requires a considerable amount of heat because it relieson heating of the entire laminate to the softening temperature. Due tothe high cost of energy, the excessive heat that is required to carryout this process makes its practicality marginal at best. In addition,the tooling that is required is unduly complex, and the costs areincreased accordingly.

SUMMARY OF THE INVENTION

The present invention is directed to an improved method and apparatuswhich takes a novel approach to the shaping of laminated thermoplasticsheets. An important feature of the invention is the use of localizedheating of the laminates only in the areas that are being bent so thatthe heat requirements are minimized and the ply slippage occurs only inthe areas that are being bent. By using localized heating and effectingply slippage in a unique way, thermoplastic laminates can be easily andeconomically formed into virtually any desired cross sectional shape.Complex shapes such as I and J sections which have not heretofore beenpractical for thermoplastic laminates can be formed in accordance withthe present invention, as can angles, channels, Z sections and otherconfigurations.

In accordance with the invention, tools having the appropriate shapesare used to effect bending of an initially flat thermoplastic laminateinto a major section having the desired section. In the case of a 180°bend, the laminate is fed through a curved passage formed between aconcave tool surface and a rotatable spool. The passage is heated sothat only the portion of the laminate that is located in the passage atany one time is heated to the softening temperature of thethermoplastic. Thus, only the portion of the laminate that is being bentis heated to a temperature at which ply slippage can occur. Theremainder of the laminate remains below the softening temperature.

In the case of shapes such as angles, channels and Z sections, two ormore tools are moved relative to one another to bend the laminate in thedesired configuration while heat is applied in a localized manner onlyto the areas of the laminate where bending is taking place. The heat ispreferably applied by heating tubes which are selectively energized anddeenergized to heat only the bend area of the laminate, thus minimizingthe energy consumption without hindering the bending operation. Morecomplicated shapes such as I and J sections can be formed by includingplies of foil such as titanium foil in the laminate and using specialtools to bend the opposite sides of the separated laminate in oppositedirections to form two flanges, again with the application of localizedheat only to the areas that are being bent.

DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which form a part of the specification andare to be read in conjunction therewith and in which like referencenumerals are used to indicate like parts in the various views:

FIG. 1 is a diagrammatic sectional view showing tooling which can beused in accordance with the present invention to achieve a bend of 180°in a flat thermoplastic laminate, with the laminate being fed toward thetooling;

FIG. 2 is a diagrammatic view similar to FIG. 1, but showing thelaminate pulled partially through the tooling;

FIG. 3 is a diagrammatic view similar to FIGS. 1 and 2 but showing thelaminate pulled more fully through the tooling around a spool by a thinsheet metal strap arrangement secured to the leading end of thelaminate;

FIG. 4 is a diagrammatic view showing a pair of tools which may be usedto bend a flat thermoplastic laminate into a Z shaped section inaccordance with the present invention, with the movable tool in itsinitial position prior to the bending of the laminate;

FIG. 5 is a diagrammatic view similar to FIG. 4 but showing the movabletool advanced to partially shape the laminate into a Z shaped section;

FIG. 6 is a diagrammatic view similar to FIGS. 4 and 5 but showing themovable tool fully advanced to form the laminate into a Z shapedsection;

FIG. 7 is a diagrammatic view showing tools which are used to form aflat thermoplastic laminate into a hat shaped channel section inaccordance with the invention;

FIG. 8 is a diagrammatic view showing tools which can be used to form aflat thermoplastic laminate into a J shaped section in accordance withthe invention, with the two movable tools in their initial positionsprior to shaping of the laminate;

FIG. 9 is a diagrammatic view similar to FIG. 8 but showing the movabletools fully advanced to form the laminate into a J shaped section; and

FIG. 10 is a fragmentary view on an enlarged scale of the upper endportion of the thermoplastic laminate shown in FIG. 8.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings in more detail and initially to FIGS. 1-3,numeral 10 generally designates a thermoplastic laminate formed bymultiple plies bonded together face to face to form a relatively thick,flat sheet. As is well known, the laminate 10 can be formed byconsolidating the plies at an elevated softening temperature of thethermoplastic and then allowing the laminate to cool to roomtemperature. At room temperature, the laminate 10 is in the form of ahard, flat sheet. The thickness of the laminate 10 can vary as desired.

In accordance with the present invention, a tool 12 has a flat bedportion 14 which leads to a uniformly curved concave surface 16 formedon the tool 12. The concave surface 16 curves through an arc which inthe illustrated embodiment is approximately 180°. Suitable supportplates 18 may be provided to support the tool 12.

The tool 12 is heated by a plurality of heating tubes 20 which arearranged in an arcuate pattern extending generally along and adjacent tothe concave surface 16. The heating tubes 20 are spaced apart from oneanother along substantially the entire extent of surface 16. The tubes20 may be heated by any suitable means. Preferably, the tubesincorporate infrared heaters, but other types of heating elements may beemployed as well.

A cylindrical spool 22 is supported for rotation about a central axis 23which may extend between the support plates 18. This spool 22 may alsobe heated as required to attain forming temperature in the laminate. Thecylindrical outside surface of the spool 22 is spaced from the concavesurface 16 of tool 12 and cooperates therewith to form a curved passage24 having a uniform width substantially equal to the thickness of thelaminate 10. Passage 24 extends through an arc of approximately 180°,although other configurations are possible.

The passage 24 has an outlet end 26 formed between upper and lowerblocks 28 and 30. Blocks 28 and 30 are maintained at a temperature wellbelow the softening temperature of the thermoplastic material whichforms the laminate 10, and the laminate is thus cooled below thesoftening temperature in the outlet portion 26 of the passage.

In order to form the laminate 10 into a 180° bend, the laminate isinitially trimmed to the width of the spool 22. The heating tubes 20 areenergized to heat the concave surface 16 to a temperature at least asgreat as the softening temperature of the thermoplastic which is to beformed. Obviously, if necessary in view of the particular laminate beingformed, spool 22 may also be heated at this time. Normally, thistemperature is in the range of approximately 650°-700° F. By heating thesurface 16 and spool 22, if necessary, passage 24 is heated to in turnheat the portion of the laminate which is fed into the curved passage24.

The laminate 10 is disposed flatly on the bed 14 with a leading marginaledge disposed between the ends of an elongated, flexible strap 35 whichmay be of sheet metal or the like. Strap 35 is bent back upon itself andlooped around a transversely circular shaft 37. One end of a shortlength of cable 39 is attached to shaft 37 and the other end of cable 39is attached to an end of a spring 41. The other end of spring 41 isattached by a cable 43 to a pulling unit (not shown).

The flexible straps 34 are firmly secured to laminate 10 by suitableclamps 36.

The laminate 10 is slowly pulled on the bed such that its leading end10a is extended into the through the heated passage 24. As the leadingend portion of the laminate is fed into passage 24, it is heated to thesoftening temperature at which the plies of the thermoplastic laminateslip relative to one another. This ply slippage permits the laminate togradually and smoothly bend in conformity with the curved shape ofpassage 24 which applies a bending force to the laminate as it is fedthrough the passage. Since the plies which are relatively far from thespool 22 must travel a greater distance than plies which are closer tothe spool, ply slippage is necessary, and the leading end 10a of thelaminate assumes the beveled configuration shown in FIG. 2 as it passesthrough the passage 24. Once the leading end 10a has reached the outlet26 of the passage, its bending is complete and no additional plyslippage need occur in that part of the laminate. The leading end 10a iscooled below the softening temperature as it passes through therelatively cool outlet 26 of the passage, and the trailing portions ofthe laminate are subsequently bent, as they pass through the passage 24and are heated by the heat generated by the heating tubes 20 and heatedspool 22, and cooled as they pass through outlet 26. Controlled tensioncan be maintained on cable 43 in order to pull the laminate into thepassage in the desired fashion. Spring 41 serves to assure uniformity ofthe forces on the laminate during the forming operation.

The laminate can be pulled through the passage 24 any desired distance.In order to form a 180° bend 10c near the center of the laminate, thefeeding can be terminated at the position shown in FIG. 3. The heatingtubes 20 and the means for heating spool 22 can then be deenergized tocool the tool and the laminate. Once the laminate has cooledsufficiently to harden, the spool 22 can be released and removed, andthe bent laminate 10 can then be removed from the tool assembly.

It is important to recognize that only the passage 24 is heated so thatheat is applied only to the portion of the laminate that is being bentat any one time. Consequently, the laminate is heated only in thoseareas at which ply slippage is required to effect the necessary bend inthe laminate, and this localized application of heat to the laminateconserves energy while at the same time allowing the ply slippage tooccur as required. The trailing end portion 10b of the laminate whichremains on the bed 14 at the time the feeding of the laminate isterminated is not heated at all and remains in the hardened condition atall times. By avoiding the heating of the entirety of the laminate 10,the possibility of delamination is minimized, and the plies are tightlybonded together throughout the laminate at the end of the formingoperation.

Referring now to FIGS. 4-6, the principles of the present invention canbe used to form an initially flat sheet of thermoplastic laminate 40into a Z shaped section. A stationary tool 42 has a flat forming surface44 on one side and a flat clamping surface 46 on an adjacent side. Theforming and clamping surfaces 44 and 46 intersect at a right angle atone corner of the stationary tool 42. This corner is radiused to theinside bend radius desired for the finished part. A plurality of heatingtubes 48a, 48b, 48c and 48d are provided in the stationary tool 42 andare arranged in a straight row extending generally along and adjacent tothe forming surface 44. The heating tubes may be infrared heating tubesor any other suitable type of heating elements.

A clamping block 50 is used to clamp one end portion of the laminate 40against the clamping surface 46. The clamping block 50 is movable towardand away from surface 46 and cooperates therewith to form a thin passageor channel 52 therebetween. The end portion of the laminate is receivedin the passage 52. A suitable clamp mechanism 54 serves to rigidly clampthe laminate 40 in channel 52 against the clamping surface 46. Theclamping block 50 is provided with a single heating tube 56 which islocated adjacent to the intersection between the forming and theclamping surfaces 44 and 46 of tool 42.

The clamping block 50 projects slightly beyond the forming surface 44 oftool 42, and a flat guide surface 58 is presented on the end of theprojecting portion of block 50. The guide surface 58 is offset from theforming surface 44 by a distance substantially equal to the thickness ofthe laminate 40.

A movable tool 60 cooperates with the stationary tool 42 and can bemoved generally along the forming surface 44 of the stationary tool.Numeral 62 identifies the rod of a hydraulic cylinder which serves toreciprocate the movable tool 60 between the positions shown in FIGS. 4and 6.

The movable tool 60 has a flat forming surface 64 which is parallel tothe forming surface 44 of the stationary tool. Intersecting with formingsurface 64 at a right angle is a slide surface 66 formed on the leadingend of the movable tool 60. This corner is radiused with an identicalradius to that between surface 46 and surface 44 and serves to form theinside bend radius of the finished part. A pair of heating tubes 68 areprovided in the movable tool and are spaced apart from one anotheradjacent to the slide surface 66.

A guide block 70 cooperates with the slide surface 66 to form a passageor channel 72 which receives the thermoplastic laminate 40. A spring 74continuously urges the guide block 70 toward surface 66 in order tomaintain the laminate 40 against the slide surface while at the sametime permitting the laminate to slide along the slide surface due to theresiliency of the spring. The guide block 70 is provided with a pair ofheating tubes 76 which are spaced apart from one another and locatedadjacent to the channel 72.

The guide block 70 projects beyond the forming surface 64 of the movabletool 60. A flat guide surface 78 formed on block 70 is offset from theforming surface 64 of the movable tool by a distance substantially equalto the thickness of the laminate 40. Guide surface 58 is in constantcontact with forming surface 64, and the other guide surface 78 is inconstant contact with the other forming surface 44.

The laminate 40 can be bent into a Z shaped section by initiallyinserting the laminate into the aligned channels 52 and 72, as shown inFIG. 4. The end portion of the laminate is rigidly clamped in channel 52and against the clamp surface 46 by tightening the clamp 54. Afterforming temperature is reached in laminate 40, a pre-determined forcecan be exerted by the cylinder rod 62 to move the movable tool 60 to theright. The path of movement of the movable tool is perpendicular to thechannels 52 and 72 and maintains the forming surfaces 44 and 64 parallelto one another and uniformly spaced apart a distance substantially equalto the thickness of the laminate 40.

Before the movement of the movable tool 60 begins, heating tube 56 isenergized along with both of the heating tubes 68 and both of theheating tubes 76. However, only the first heating tube 48a of thestationary tool is energized at this time. As soon as formingtemperature is reached, and the movable tool begins to move, only theportion of the laminate adjacent the intersection between surfaces 44and 46 is heated from opposite sides thereof by the energized heatingtubes. The heat is thus applied to the laminate in a localized mannerand is sufficient to raise the temperature to the softening temperaturenecessary to permit the plies of the laminate to slip relative to oneanother. Therefore, as the movable tool 60 is moved from the position ofFIG. 4 toward the position of FIG. 5, the ply slippage resulting fromthe localized application of heat permits the laminate to bend through aright angle at the intersection between surfaces 44 and 46 where thebending force is applied. The laminate also bends through a right angleat the intersection between surfaces 64 and 66. The ply slippage isequal and opposite at the two corners, so no ply slippage occursanywhere else in the laminate. As the movement of tool 60 progresses,the force of spring 74 maintains the laminate against surface 66 whilepermitting it to slip along surface 66 in a direction parallel to thelaminate.

After the laminate has been bent at the intersection between surfaces 44and 46, heating tube 56 is deenergized. As the movable tool continues tomove to the right, the heating tubes in the stationary tool 42 areenergized and deenergized in a pattern to maintain localized heating ofthe laminate only in the area that is being bent. As channel 72 movesaway from it, tube 48a is deenergized, and heating tubes 48b and 48c areenergized in succession as the area of the laminate which is being bentprogressively moves to the right. When the position of FIG. 5 isreached, both tubes 48b and 48c are preferably energized, while tubes48a and 48d are deenergized. As tool 60 approaches the position shown inFIG. 6, tubes 48b and 48c are deenergized in succession and tube 48d isenergized since it is then located adjacent to the area at which thelaminate is being bent. Tubes 68 and 76 remain energized throughout theforming operation.

The movement of tool 60 is terminated when the position of FIG. 6 isreached. At this time, the laminate has been bent into the shape of a Zhaving its web 40a formed between the confronting forming surfaces 44and 64 and its two legs or flanges 40b formed in the channels 52 and 72.All of the heating tubes can then be deenergized to allow the laminateto cool until it hardens. Once the laminate has hardened, it can beremoved from the tools, and the movable tool can be returned to itsinitial position (FIG. 4).

The end of the laminate which is clamped in channel 52 is not heated atall, and the opposite end which is located in channel 72 at the end ofthe shaping operation has not been deformed at all. Due to the localizedapplication of heat to the laminate, only the area of the laminate whichis being bent is heated so that the heating requirements are minimizedand ply slippage is allowed only where necessary to permit the laminateto be bent as desired.

It is noted that the movement of the movable tool 60 can be terminatedat any time so that a Z section with unequal legs could be formed.Similarly, the movable tool can be moved to the right beyond theposition of FIG. 6 to form an angle member once the laminate has slippedcompletely out of channel 72.

The arrangement shown in FIG. 7 can be used to form an initially flatthermoplastic laminate 80 into a hat shaped channel section. A pair ofstationary tools are included in the arrangement of FIG. 7, and the samereference numerals are used to identify the components of the stationarytools as were used in FIGS. 4-6. Each stationary tool 42 has a clampblock 50 cooperating therewith in the same manner discussed inconnection with FIGS. 4-6. A spacer 82 is interposed between thestationary tools 42, and the forming surfaces 44 of the two tools 42face in opposite directions on opposite sides of the spacer 82.

A pair of movable tools 60 which may be identical to the movable tools60 shown in FIGS. 4-6 are included in the arrangement of FIG. 7, alongwith a guide block 70 for each movable tool. The movable tools 60 moveadjacent to the forming surfaces 44 of respective stationary tools 42 asdescribed earlier.

The laminate 80 is initially in the shape of a flat sheet formed bymultiple plies. Channels 52 and 72 are initially aligned with oneanother, and the laminate is inserted into the channels with a centralportion thereof clamped in channels 52 of the stationary tools by clamps54. When forming temperature is reached as described for FIGS. 4-6, themovable tools are moved to the right by extension of the cylinder rods62, and as the movable tools progress, the heating tubes 48a-48d areenergized and deenergized in the same pattern described in connectionwith FIGS. 4-6. Heating tubes 56 are deenergized after the initial bendsare made in the laminate at the opposite ends of the portion which isclamped in the channels 52. Tubes 68 and 76 remain energized throughoutthe forming operation.

Once the movable blocks have reached the position of FIG. 7, theirmovement may be terminated. In this position, the laminate 80 has takenthe form of a hat shaped channel member having a web 80a formed inchannels 52, sidewalls 80b formed between the confronting formingsurfaces 44 and 64, and flanges 80c formed in the channels 72 of themovable tools. It should be noted that movement of the tools 60 cancontinue until the laminate has slipped completely out of channels 72.Then, a channel without flanges will have been formed.

As in the arrangements previously described, the arrangement of FIG. 7effects localized application of heat to the laminate only at the areaswhich are being bent. Therefore, the heating requirements are againminimized and ply slippage is allowed only in the necessary area orareas of the laminate. Spacers having different sizes can be used inplace of spacer 82 to provide the channel member with a web havingvirtually any length.

The arrangement show in FIGS. 8 and 9 can be used to form athermoplastic laminate 90 into a J shaped section. A stationary tool 42and a movable tool 60 having the same construction as describedpreviously are included, along with a clamp block 50 and a guide block70. A spacer 92 is attached to the stationary tool 42 on the sideopposite the forming surface 44, and the spacer 92 presents a channel 94in alignment with channel 52 to receive the laminate.

A second movable tool 96 can be moved toward and away from the spacer 92by a rod 98 which may be the rod of a hydraulic cylinder. A cavity whichis formed in tool 96 includes a passage 100 which extends into thebottom surface of the tool and has a width substantially equal to thethickness of the laminate 90. At its top end, passage 100 intersectswith a pair of cross channels 102 which extend in opposite directionsfrom the passage 100. The cross channels 102 are aligned with oneanother and are oriented perpendicular to passage 100. Tool 96 isprovided with a plurality of heating tubes 104 which are locatedadjacent to the intersection between passage 100 and channels 102 onopposite sides of the passage and channels. At the top end of passage100, a divider in the nature of a tapered, radiused rib 106 is formed inorder to guide the laminate into the cross channels 102 as willsubsequently be described. A relatively small heating tube 104a islocated adjacent to divider 106.

Laminate 90 is provided during consolidation of the laminate from themultiple plies of material, with a pair of thin foil sheets 112interposed in the laminate to effectively separate the laminate into apair of branches 110 (FIG. 10). The foil sheets are interposed in faceto face relationship and, while each is bonded to its respectiveadjacent branch 110, the foil sheets are not bonded together. Titaniumfoil is presently preferred for this purpose in view of the similarphysical properties between titanium and commonly used laminatematerials, but other foils can be used.

The mutually unbonded foil sheets 112 provide a division betweenlaminate branches 110, and are usually placed so that the two branchesare of identical thicknesses, namely one-half of the total thicknessesof the laminate. The sheets of foil insure that the branches 110 may beeasily separated from one another. Each foil sheet has a projecting endor tab 114 which extends out of the division 108 between the branches.The space between tabs 114 provides a lead-in area which facilitatesseparation of the branches 110.

Laminate 90 can be formed into a J shaped section by initially insertingit through channels 52, 72 and 94 with the top end of the laminateextending into the passage 100 of tool 96. The central portion of thelaminate is clamped in passages 52 and 94 by tightening the clamp 54.Tool 60 can be moved to the right in order to bend the lower end of thelaminate in the manner described previously. When the laminate hasslipped completely out of channel 72, tool 60 will have reached theposition shown in FIG. 9 and its movement can then be terminated. Theheating tubes 48a-48d are energized and deenergized in the sequencedescribed earlier to apply localized heat only to the area that isundergoing bending.

Simultaneous with the movement of tool 60, tool 96 is moved downwardlytoward the spacer 92. As tool 96 moves downwardly, the divider 106enters the space between the projecting ends 114 of the foil sheets 112.Continued downward movement of divider 106 carries it between the foilsheets and into division 108 to cause the branches 110 to bend intochannels 102. The heating tubes 104 and 104a are previously energized sothat the branches 110 are bent through right angles into the crosschannels 102 as the downward movement of tool 96 continues. When tool 96has reached the position shown in FIG. 9, it is in contact with spacer92 and its movement can then be terminated. At this time, the branches102 together form a cross 90a on the top end of the J shaped laminate.The web 90b is formed in the channels 52 and 94, and the base leg 90c isformed between the confronting forming surfaces 44 and 64. Once the Jshaped section has cooled enough to harden, it can be removed from thetool assembly.

It should be evident that a tool such as the movable tool 96 can beapplied both to the top and bottom ends of a thermoplastic laminate inorder to form the laminate into an I shaped section having crosses onboth its top and bottom ends. In addition, spacers having various sizescan be used in place of spacer 92 to provide the web portion withvirtually any desired length. As in previous arrangements, the localizedmanner in which heat is applied minimizes the heating requirements whileallowing the ply slippage to occur in the areas which are being bent.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

Since many possible embodiments may be made of the invention withoutdeparting from the scope thereof, it is to be understood that all matterherein set forth or shown in the accompanying drawings is to beinterpreted as illustrative and not in a limiting sense.

Having thus described the invention, I claim:
 1. Apparatus for shaping athermoplastic laminate having multiple plies, said apparatuscomprising:first and second tools having confronting forming surfacesspaced apart to accommodate the thickness of the laminate therebetween,one of said tools being movable relative to the other along a pathmaintaining said forming surfaces substantially parallel to one another;a clamping surface on said first tool intersecting with the formingsurface thereof at a first area; means for rigidly clamping apreselected portion of the laminate against said clamping surface; aslide surface on said second tool intersecting with the forming surfacethereof at a second area; means for maintaining the laminate againstsaid slide surface while permitting the laminate to slip along the slidesurface as said one tool is moved along said path; and means forapplying heat to the laminate in a localized manner as said one tool ismoved along said path to raise the temperature of the laminate adjacentsaid first and second areas to a level at which the plies slip along oneanother, whereby the ply slippage permits the laminate to bend adajcentsaid first and second areas during movement of said one tool along saidpath.
 2. Apparatus as set forth in claim 2, wherein said heat applyingmeans includes a plurality of heating elements arranged in a rowextending generally along the forming surface of said first tool, eachheating element being energized when said second area is locatedadjacent thereto and deenergized when said second area is locatedremotely.
 3. Apparatus as set forth in claim 2, wherein said heatapplying means further includes a plurality of heating elements arrangedin a row extending generally along said slide surface of the second tooland energized during movement of said one tool along said path. 4.Apparatus as set forth in claim 1, including:guide blocks on said firstand second tools projecting beyond the forming surfaces thereof and eachengaging the forming surface of the other tool to maintain substantiallyconstant spacing between said forming surfaces.
 5. Apparatus as setforth in claim 1, wherein:said clamping means includes a clamping blockand means for clamping said clamping block to said first tool to clampsaid preselected portion of the laminate against said clamping surfaces;and said means for maintaining the laminate against said slide surfaceincludes a guide block and resilient means for urging said guide blocktoward said slide surface to maintain the laminate against same whilepermitting slipping of the laminate along said slide surface. 6.Apparatus as set forth in claim 1, wherein said clamping surface andforming surface of the first tool are substantially perpendicular andsaid slide surface and forming surface of the second tool aresubstantially perpendicular to shape the laminate into the generalconfiguration of a Z having a web portion thereof formed between saidforming surfaces and leg portions thereof formed along said clampingsurface and said slide surface.
 7. Apparatus for shaping a thermoplasticlaminate having multiple plies, said apparatus comprising:first andsecond tools each having a cavity for receiving the laminate, one ofsaid tools being movable relative to the other along a prescribed path;means for rigidly clamping a preselected portion of the laminate in thecavity of the first tool; said cavity of the second tool having apredetermined area shaped to effect bending of the laminate therein intoa preselected configuration as said one tool moves along said prescribedpath; and means for applying heat to said predetermined area in alocalized manner as said one tool moves along said prescribed path, saidheat being sufficient to raise the temperature of the laminate adjacentsaid predetermined area to elevated temperature at which the plies slipalong one another to permit the laminate to bend into said preselectedconfiguration during movement of said one tool along said prescribedpath.
 8. Apparatus as set forth in claim 26, wherein:a separation isformed in one edge portion of the laminate to provide a pair ofseparated branches in the laminate on opposite sides of the separation;said cavity of the second tool includes a passage extending into thesecond tool for receiving said one edge portion of the laminate and apair of cross channels extending in opposite directions from saidpassage at an angle thereto; said prescribed path carries said first andsecond tools toward one another to effect bending of said branches inopposite directions into said cross channels, whereby the branchescooperate to form a cross on the laminate; and said prescribed area islocated adjacent the intersection between said passage and crosschannels.
 9. Apparatus as set forth in claim 8, including a pair of foilsheets bonded to the respective branches within the separation, saidfoil sheets being detached from one another to facilitate separation ofthe branches as the same enter said cross channels, and furtherincluding means engageable between said foil sheets for guiding saidbranches into the respective channels.
 10. Apparatus as set forth inclaim 9, wherein each foil sheet has an edge projecting out of theseparation beyond said one edge portion of the laminate, said edges ofthe foil sheets providing a lead-in to facilitate separation of the foilsheets and the respective branches, and said means engageable betweensaid foil sheets being engageable between said edges of the foil sheets.11. Apparatus as set forth in claim 8, including:a third tool locatedadjacent a side of the first tool opposite said second tool, said firstand third tools having confronting forming surfaces spaced apart toaccommodate the thickness of the laminate therebetween; meansestablishing a path along which said third tool is movable relative tosaid first tool, said path maintaining substantially constant spacingbetween said forming surfaces; a slide surface on said third toolintersecting with the forming surface thereof at a second predeterminedarea; means for maintaining the laminate against said slide surfacewhile permitting the laminate to slip along the slide surface as thethird tool moves along said path; and means for applying heat to saidsecond predetermined area in a localized manner as said third tool movesalong said path to raise the temperature of the laminate adjacent saidsecond predetermined area to said elevated level, whereby the sheet canbe shaped into the general configuration of a J having a base legportion thereof formed between said forming surfaces.